Apparatus and method for assembling sheet material mounting device components

ABSTRACT

The present invention provides a sheet material mounting device having two channels, namely, a mounting channel for receivably engaging a rod for gripping the sheet material and a spacer channel for receivably engaging a spacer support configured to engage a lift cord and, optionally, a spacer cord. The spacer channel may be positioned above the mounting channel such that the center of gravity of the mounting device is located above the center of the mounting channel, thereby reducing asymmetric tilt of the sheet material engaged by the mounting channel and reducing friction against the lift cord. Alternatively, the mounting channel may be positioned above the spacer channel. The mounting channel and the spacer channel are preferably both C-shaped, and each channel has an opening which faces in a direction opposite the direction faced by the opening of the other channel. Thus, a side view of the mounting device may resemble either an “S” or a reverse “S”. In accordance with another aspect of the invention, there is provided an apparatus and method for assembling the components of a sheet material mounting device, such that the assembled components of each sheet material mounting device are capable of maintaining vertical alignment with respect to every other sheet material mounting device comprised by the window covering system. Moreover, there is provided an apparatus and method for adjusting and re-aligning assembled components of a sheet material gripping apparatus.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation-in-part of U.S. patentapplication Ser. No. 09/408,228, filed Sep. 29, 1999.

FIELD OF THE INVENTION

[0002] The present invention relates generally to an apparatus andmethod for mounting sheet material to a support structure and, moreparticularly, to an apparatus and method for assembling the componentsof a window covering system, such as a Roman shade window coveringsystem.

BACKGROUND OF THE INVENTION

[0003] The prior art contains various devices for mounting, lifting, andfolding flexible sheet material in association with blinds, curtains,draperies, and other window coverings. Some of these window shadedevices include guide cables and lift cords in conjunction with afabric-gripping device. These cables/cords are typically threadedthrough rings sewn to the shade fabric. Alternatively, the cables/cordsare threaded through apertures in the fabric pleats, wherein the pleatsmay be formed or stiffened with slats. The lattice formed by theattachment of the shade fabric to these guide cables and lift cordsconstitutes a mobile support structure which allows the shade to travelbetween raised and lowered positions.

[0004] Roman shades are a particular type of window covering whichincorporates a mobile support structure such as a lattice for gatheringsheet fabric into substantially horizontal folds. One example of theconstruction of a contemporary Roman shade is a cloth fabric hangingfrom a head rail, with a lower end having weights at predeterminedlateral intervals. This type of Roman shade can be raised by drawing upa lift cord such that large, loose folds in the fabric are formed atapproximately equal vertical distances to provide a neatly pleatedaesthetic appearance. A common configuration for connecting the cord tothe shade is to sew at least two sets of rings or connectors in verticallines along the back of the fabric material as shown in U.S. Pat. No.1,321,800 entitled CURTAIN HANGER issued to Andress, et al. on Nov. 18,1919. In this type of Roman shade, a lift cord passes from a head railthrough each set of rings and is then either fastened to the bottom edgeof the fabric or wrapped around the bottom edge of the fabric andreturned up the front face of the shade to the head rail. Alternatively,each set of rings or connectors is sewn to the sheet fabric and attachedto a lift cord at predetermined vertical intervals. As the shade travelsthrough raised positions, the interval between the connectors may bereduced.

[0005] However, due to the extensive time and labor to sew connectors tothe back of the sheet material of a Roman shade, the art has developedother methods and devices to connect sheet fabric to a mobile supportstructure. In the shade system disclosed in U.S. Pat. No. 4,694,545entitled ATTACHMENT OF RINGS WITHOUT SEWING issued to Dernis on Sep. 22,1987, a set of U-shaped filaments are inserted through the fabric fromthe front face. The ends of each filament are gathered in a tube, bentover the end of the tube and held in place by a sleeve that fits overthe tube.

[0006] Another alternative for attachment includes one or morehorizontal ribs to provide support and to maintain spacing between thecords which are oriented vertically across the back of the fabric. Forexample, in U.S. Pat. No. 5,207,256 entitled SAFETY DEVICE FOR ARAISABLE CURTAIN DOOR issued to Kraeutler on May 4, 1993, the ribs areplaced in vertically spaced, transverse pockets in the sheet material.However, in this system, the pockets must be sewn into the sheetmaterial, thereby substantially adding to the time, effort, and expenseof manufacture.

[0007] U.S. Pat. No. 5,273,096, entitled APPARATUS FOR GRIPPING SHEETFABRIC issued to Thomsen et al. on Dec. 28, 1993, discloses a tubularmember having a longitudinal opening which receives the fabric and arod, thereby gripping the fabric between the member and the rod. Thebackside of the tubular members each include loops through which thelift cords pass. However, as shown in FIG. 10, if this system is used ona Roman shade for a large window, the combined weight of the tubularmember and the rod will often cause tilting of the mounting device,thereby adding substantial friction to the lift cord and making it moredifficult to raise the shade. More particularly, the fabric mountingdevice found in Thomsen et al. and other Roman shade systems employdesigns wherein the center of gravity of the fabric mounting devicecauses the device to tilt asymmetrically as the shade is raised,distorting the fabric being held and thereby adding friction to the liftcord. Thus, the size of a Roman shade is often limited by the frictionincident upon the lift cord caused by the tilting of one or more of therings, connectors, loops, or spacers used to mount the fabric to thelift cord.

[0008] A need exists for a light-weight, sheet-material grippingapparatus which can be quickly assembled by the manufacturer and whichincludes both light-weight and inexpensive spacers that can be connectedto the sheet material without sewing. Moreover, the gripping apparatuscomponents should reduce the lift cord friction which often increasesasymmetric tilting of the sheet-material connectors as the apparatus israised. Additionally, there is a need for an apparatus and method foreasily and rapidly assembling tightly fitted components of a sheetmaterial gripping apparatus such that, once assembled, the components ofeach sheet material gripping apparatus are capable of maintainingvertical alignment with respect to other sheet material grippingapparatus comprised by the window covering system. Moreover, there is aneed for an apparatus and method for easily adjusting and re-aligningassembled components of a sheet material gripping apparatus.

SUMMARY OF THE INVENTION

[0009] The present invention provides a sheet material mounting devicehaving two channels, namely, a mounting channel for receivably engaginga rod for gripping the sheet material and a spacer channel forreceivably engaging a spacer support configured to engage a lift cordand, optionally, a spacer cord. The spacer channel may be positionedabove the mounting channel such that the center of gravity of themounting device is located above the center of the mounting channel,thereby reducing asymmetric tilt of the sheet material engaged by themounting channel and reducing friction against the lift cord.Alternatively, the mounting channel may be positioned above the spacerchannel. The mounting channel and the spacer channel are preferably bothC-shaped, and each channel has an opening which faces in a directionopposite the direction faced by the opening of the other channel. Thus,a side view of the mounting device may resemble either an “S” or areverse “S”. In accordance with another aspect of the invention, thereis provided an apparatus and method for assembling the components of asheet-material mounting device, such that the assembled components ofeach sheet material mounting device are capable of maintaining verticalalignment with respect to every other sheet material mounting devicecomprised by the window covering system. Moreover, there is provided anapparatus and method for adjusting and re-aligning assembled componentsof a sheet material gripping apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The features and advantages of the present invention reside inthe details of construction and operation as more fully depicted,described, and claimed below, with particular reference to theaccompanying drawings, wherein like numerals refer to like partsthroughout, and wherein:

[0011]FIG. 1 is a three-quarter perspective view of an exemplary shadeclamp according to one embodiment of the present invention;

[0012]FIG. 2A is a perspective view of an exemplary spacer according toone embodiment of the present invention;

[0013]FIG. 2B is a perspective view of an exemplary spacer with the lugportion removed according to one embodiment of the present invention;

[0014]FIG. 3 is a three-quarter perspective view of a portion of anexemplary rod according to one embodiment of the present invention;

[0015]FIG. 4 is a three-quarter perspective, exploded view of anexemplary sheet-material mounting apparatus depicting the positionalrelationship of the component parts according to one embodiment of thepresent invention;

[0016]FIG. 5 is a three-quarter perspective view with arrows depictingan exemplary method of receivably engaging a V-spring and spacer withinopposed shade clamp channels according to one embodiment of the presentinvention;

[0017]FIG. 6 is a side elevation view of an exemplary shade clampprepared to receive a welting of sheet material for subsequent grippingwith a rod according to one embodiment of the present invention;

[0018]FIG. 7 is a side elevation view of an exemplary shade clamp havingreceivably engaged a V-spring and a welting of sheet material accordingto one embodiment of the present invention;

[0019]FIG. 8 is a side elevation view of an exemplary shade clampattached to a support structure and having receivably engaged aV-spring, a welting of sheet material and a spacer, wherein the spacerincludes a lift cord and spacer cord, according to one embodiment of thepresent invention;

[0020]FIG. 9 is a side elevation view of an exemplary shade clampattached to a support structure and having receivably engaged av-spring, a welting of fabric and a spacer, wherein the spacer includesa lift cord and spacer cord, according to an alternative embodiment ofthe present invention;

[0021]FIG. 10 is a side view of a prior art device showing theasymmetric tilting of the gripping devices;

[0022]FIG. 11A is a bottom view of a center support bracket according toone embodiment of the present invention;

[0023]FIG. 11B is a front view of a center support bracket according toone embodiment of the present invention;

[0024]FIG. 11C is a rear view of a center support bracket according toone embodiment of the present invention;

[0025]FIG. 12 is an exploded view of the housing assembly showing theend caps and wall brackets according to one embodiment of the presentinvention; and,

[0026]FIG. 13 is a side cut-away view of a support assembly showing acenter support bracket, housing and shade clamp according to oneembodiment of the present invention.

[0027] FIGS. 14A-E illustrate a side perspective view of an exemplarytool for assembling and aligning the components of a sheet materialmounting device.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0028] The following detailed description of exemplary embodiments ofthe present invention makes reference to the accompanying drawings,which form a part hereof and in which are shown, by way of illustration,exemplary embodiments in which the invention may be practiced. Theseexemplary embodiments are described in sufficient detail to enable thoseskilled in the art to practice the invention, and it should beunderstood that other embodiments may be utilized and that logical andmechanical changes may be made without departing from the spirit andscope of the present invention. Thus, the following detailed descriptionis presented for purposes of illustration only and not of limitation,and the scope of the present invention is defined solely by the appendedclaims.

[0029] The present invention preferably includes an apparatus and methodfor reducing a shade clamp's tilt and reducing the excess frictionbetween a shade clamp (or channel guide) and a lift cord. One skilled inthe art will appreciate that the shade clamp may be any device orcombination of devices suitably configured to hold sheet material. Forexample, any clamp, clip, ring, fastener, mechanical device, electricaldevice, magnetic device, VELCRO™ device and/or the like. Moreover, theshade clamp is comprised of any suitable material which providessufficient characteristics for holding the sheet material, such as, forexample, any type or combination of plastic, metal, rubber, wood,magnet, textile, glass and/or the like. Further, one skilled in the artwill appreciate that the sheet material is any material capable of beingheld by shade clamp, such as, for example, any type or combination ofcloth, textile, roman shade, pleated roman shade, wood, metal, animalskin, plastic, mesh, weave, and/or the like. In an exemplary embodiment,the sheet material is a piece of material in the form of a roman shade.

[0030] A suitable support structure is any structure capable ofsupporting the shade clamp and material, such as a headrail, cord,and/or spacers. With momentary reference to FIG. 13, an exemplary shadesystem includes shade clamp 1 (only one shown), housing 90, centerbracket 71, lift tube 112, facie 110, and other components of the systemwhich will be described in more detail below. The present system may beused in conjunction with any shade operator device, such as a wrapspring shade operator as in “Wrap Spring Shade Operator” with inventorsJoel Berman, Vincent J. Brown, Victor Erlikh and John Wilk filed on Aug.23, 1999 having U.S. Ser. No. 09/379,065, the entire application isincorporated herein by reference.

[0031] Referring now to FIG. 1, in accordance with one embodiment, ashade clamp 1 grips and mounts flexible sheet material 60 to a hangingsupport structure. The S-shaped shade clamp 1 is preferably rotationallysymmetric about the central axis of clamp 1 and has opposed channels 45a, 45 b, wherein mounting channel 45 b reciprocally receives a weltingof sheet material 60 and spacer channel 45 a receives a spacer support5, shown in FIG. 4. The clamp 1 preferably includes interior retaininglips 35 a, 35 b and peripheral retaining lips 40 a, 40 b wherein aninterior and peripheral retaining lip pair secures the welting of sheetmaterial 60 or the spacer support 5 within opposed channels 45 a, 45 bby restricting the exit path. Each interior lip 35 and peripheral lip 40pair defines opposed lateral openings 30 a, 30 b which provide access toopposed channels 45 a, 45 b, respectively. The welting of sheet material60 is releasably nested in the mounting channel 45 b with a positivepressure against the inside surface of the channel requiring no furthertension or clamping. The interior lip 35 b and peripheral lip 40 b ofthe mounting channel lateral opening 30 b serve the dual purpose ofpreventing random release of the secured welting and providing for the30 neat pinching of the exterior sheet material so as to obscure theview of rod 10, shown in FIG. 3, within the mounting channel 45 b. In apreferred embodiment, the welting of sheet material 60 and the spacersupport 5 are removably held within opposing channels 45 a, 45 b byinterior lips 35 a, 35 b and peripheral lips 40 a, 40 b, respectively;however, those skilled in the art will also recognize various othermeans and methods that may be alternatively or conjunctively used withinthe scope of the present invention, such as any device or combination ofdevices suitably configured to restrict the exit path of material 60 orspacer support 5. For example, a release pin, clasp, snaps, adhesiveand/or the like.

[0032] As shown in FIGS. 2A and 2B, spacer support 5 is configured forguiding the lift/guide cord 65, optionally attaching to spacer cord 70,and being receivably engaged by spacer channel 45 a. As best shown inFIG. 2A, the spacer support 5 has an enlarged cylindrical end 25 whichtapers down on its outside edge, thereby forming an arrowhead likeconfiguration. Cylindrical end 25 is configured for nesting withinspacer channel 45 a between the inside surface of spacer channel 45 a,the interior channel lip 35 a and the peripheral channel lip 40 a. Thoseskilled in the art will also recognize various other means and shapesthat may be alternatively or conjunctively used which are considered asbeing within the scope of the present invention, such as any device orcombination of devices suitably configured to engage the spacer channel45 a. For example, a pin, rod, clasp, adhesive, and/or the like.Moreover, spacer support 5 can be integral with shade clamp 1 as asingle-piece construction. Spacer support 5 itself can also be of singlepiece construction. In a preferred embodiment, spacer support 5 is clearrigid PVC material with UV protection; however, any suitable materialsuch as plastic, metal, wood and/or the like is within the scope of thepresent invention.

[0033] With reference to FIGS. 2A and 4, a planar flange 50 is attachedto the longitudinal surface of cylindrical end 25, such that flange 50,when spacer support 5 is inserted into spacer channel 45 a, protrudesoutwardly from the channel opening 30 a. In a preferred embodiment,spacer flange 50 includes an aperture 20 which receives lift cord 65therethrough. The lift cord aperture 20 is positioned on the spacerflange 50 at a predetermined distance away from cylindrical end 25. In apreferred embodiment, spacer support 5 is molded around spacer cord 70,thereby providing a secure attachment between cord 70 and spacer support5. In a particularly preferred embodiment, spacer support 5 includes acylindrical projection 53 which extends above and below spacer support5. In this embodiment, cylindrical projection 53 is also molded aroundspacer cord 70, thereby increasing the support by spacer support 5around spacer cord 70. Cylindrical projection 53 may be any suitablematerial, may project above and/or below spacer support 5, may be moldedas a single unit with spacer support 5, may be a separate component(such as a dowel, washer, etc.), and may be located anywhere on spacersupport 5. One skilled in the art will appreciate that the presentsystem can include more than one lift cord 65 or more than one spacercord 70, and aperture 20 can be of any size, located anywhere on spacersupport 5, additional apertures can exist on spacer support 5 or cords65, 70 may be suitably attached, by clip, glue and/or the like, to anyportion of the spacer support 5. Moreover, spacer support 5, or anyportion of spacer support 5, may be formed around, and fused to, spacercord 70 and/or lift cord 65, thereby eliminating the need for theaperture 20.

[0034] With particular reference to FIG. 2B, spacer support 5 preferablyincludes an elliptical notch 54 on the cylindrical end 25 which receivesa plate 52. Notch 54 preferably includes a protruding, convex ridgealong its inner circumference for receiving the side-slotted groovealong the outer circumference of the side surface of plate 52. Plate 52is preferably an elliptical device with a first rounded end with a flatupper and lower surface and a second enlarged cylindrical end 25 whichtapers down on its outside edge, thereby forming an arrowhead likeconfiguration. In a preferred embodiment, if a spacer cord 70 is used,plate 52 and cylindrical projection 53 (as discussed above) is moldedaround spacer cord 70 such that spacer cord 70 travels through the flatupper and lower surface of plate 52. One skilled in the art willappreciate that the plate 52 and notch 54 configuration can be anyconfiguration and can include any suitable means for attaching plate 52to spacer support 5 (groove, clip, etc.), or alternatively, spacersupport 5 can be a one piece configuration without a removable plate 52.

[0035] More particularly, if it is desired that sheet material 60 layflat without pleating or the like (for example, in the case of sheetmaterial 60 comprising a detailed pattern), plate 52 and spacer cord 70may be eliminated from the system. However, if pleating or the like isdesired (for example, in the case of sheet material 60 comprising asolid color), the incorporation of plate 52 and spacer cord 70 intospacer support 5 helps form the pleats.

[0036] Rod 10 is any device configured for securing sheet material 60within the mounting channel 45 b of the shade clamp 1. As best shown inFIG. 3 (which shows a portion of the elongated rod 10 in a V-spring clipembodiment), rod 10 is preferably one piece and has a length equal tothe width of the shade. Alternatively, rod 10 is many clips, rods, orthe like which are inserted into mounting channel 45 b at variouslocations. Rod 10 is preferably a V-spring having depressible wings 55a, 55 b for releasably securing a welting of the sheet material 60. Asbest shown in FIG. 6, the V-spring wings 55 a, 55 b are compressed tocollapse the rod 10 for subsequent insertion into the mounting channel45 b through the mounting channel lateral opening 30 b. After insertioninto channel 45 b, the rod 10 is released and the wings 55 a, 55 bexpand to provide a force against the inner surface of channel 45 b,thereby sandwiching the sheet material 60 in mounting channel 45 b andrestricting the movement of sheet material 60. Those skilled in the artwill also recognize various other means and shapes that may bealternatively or conjunctively used which are within the scope of thepresent invention, such as, for example, a rod, a pin, clasp, VELCRO™,adhesive, snaps and/or the like. Alternatively, rod 10 could beeliminated and material 60 can be wrapped around the outside of mountingchannel 45 b and optionally clamped to the outside of mounting channel45 b by any of the aforementioned clamping devices.

[0037] The positional arrangement of the component parts of the sheetmaterial mounting apparatus is best shown in FIG. 4. Spacer support 5receivably engages through side insertion into spacer channel 45 a ofshade clamp 1 and the rod 10 receivably engages through side insertionthe mounting channel 45 b of the clamp 1. An alternative method ofreceivably engaging both the spacer support 5 and the rod 10 in theirrespective channels 45 a, 45 b is shown by the arrows of FIG. 5 whereinthe components are pushed into their respective channels throughopenings 30 a, 30 b, respectively. Those skilled in the art will alsorecognize various other methods that may be alternatively orconjunctively used which are within the scope of the present invention,such as any arrangement or methods for receivably engaging, such as, forexample, rotating the components into the channels, permanentsingle-piece construction and/or the like.

[0038] As is best shown in FIG. 6, prior to receivably engaging awelting of sheet material 60, the sheet material 60 is placed betweenthe mounting channel 45 b and the rod 10. As the upper wing 55 a andlower wing 55 b of the rod 10 are compressed, the rod 10 is pushedthrough the lateral opening 30 b of the mounting channel 45 b or slidthrough the side, forcing a welting of fabric 60 into the mountingchannel 45 b as shown in FIG. 7. Alternatively, a welting of sheetmaterial 60 can be wrapped around the exterior surface of the rod 10 andthen depressed and forced through the lateral opening 30 b (or slidthrough the side).

[0039] With the guide spacer channel 45 a opening the opposite directionto the sheet-material mounting channel 45 b, the receivably engagedspacer support 5 is positioned to bear a large percentage of the weightof the sheet material 60 at a point approximately directly above thepoint of sheet material attachment within channel 45 b. Thisconfiguration positions the center of gravity of the apparatus moredirectly above the mounting channel 45 b which has the effect ofreducing asymmetric tilting of the sheet-material mounting apparatus asthe lift cord 70 is raised. This in turn reduces the friction incidentupon the lift cord 70 as the shade travels through raised positions andreduces the pulling force needed to lift the shade.

[0040] One method of attachment of clamp 1 to the support structure of alift cord 65 and spacer cord 70 is shown in FIG. 8. As the lift cord 65is raised, the spacer support 5 is engaged at a predetermined point toraise and travel with the lift cord 65. The spacer cord 70 is a staticline that provides a guide for a plurality of spacer supports 5 totravel along as the shade is moved through raised positions. The spacercord 70 also assists with preventing torquing of the spacer supports 5as the lift cord 65 is raised.

[0041]FIG. 9 shows an alternative configuration for reducing frictionincident upon the lift cord 70. In this alternative embodiment of thepresent invention, the receivably engaged spacer support 5 is positionedto bear the weight of the sheet material 60 at a point directly belowthe point of sheet material attachment to mounting channel 45 b. Thisconfiguration positions the center of gravity of the apparatus moredirectly below the mounting channel 45 b which similarly has the effectof reducing asymmetric tilting of the sheet-material mounting apparatusas the lift cord 65 is raised. The alternative embodiment of the presentinvention depicted in FIG. 9 reduces the friction incident upon the liftcord 65 as the shade travels through raised positions as well.

[0042] With respect to FIGS. 11A-C, various views of a center supportbracket 71 is shown. Center support bracket 71 is any suitable deviceconfigured to support the lift tube 112 (shown in FIG. 13), housing 90,facie 110 (shown in FIG. 13), spacer support 5, and fabric mount whileproviding a guide for the lift cords 65. One skilled in the art willappreciate that bracket 71 is of any configuration and comprised of anysuitable material. Moreover, bracket 71 can be one moldedmulti-functional component or can be a plurality of components whichperform one or more of the aforementioned functions. In a preferredembodiment, bracket 71 includes a central circular opening 76 forsupporting the lift tube 112. Top and rear rectangular plates 78 areattached to opening 76 by a lattice structure which is perpendicular tothe surface of opening 76. Rectangular plates 78 include lips around itsperiphery such that plates 78 are suitably configured to attach bracket71 to housing 90 by slidably engaging the lips into channels 94. Thefront of bracket 71, as best seen in FIG. 11B, preferably includes arectangular facie plate 80 with a lip on its periphery for slidablyengaging facie. One skilled in the art will appreciate that plates 78and 80 can attach to other parts by any suitable means, including forexample, snaps, VELCRO™, adhesives and/or the like, or can be integralwith the other components. Below plate 80, towards the bottom of bracket71, is an angled ledge 82 which is configured to support the fabricmounting spline. As best seen in FIG. 11A, below ledge 82, and on thebottom of bracket 71, are two opposing notches 72 which open to theoutside surfaces of bracket 71 and a circular slot 73. Notches 72 andslot 73 are suitably configured to retain spacer support 5. Also, on thebottom of bracket 71 and further towards the rear surface, there arepreferably four apertures 74 which are suitably configured to guide thelift cord 65, wherein two of the holes on the same side are for twodifferent cords depending on the left or right configuration of thecords.

[0043] With respect to FIG. 12, an exemplary housing assembly 90 isshown. Housing assembly 90 is any suitable device or combination ofdevices in any suitable configuration for supporting center bracket 71and facie 110 and comprised of any suitable material such as plastic,PVC, metal, aluminum, wood, and/or the like. In a preferred embodiment,housing 90 includes L-shaped plate 92 comprised of extruded aluminum,end caps 96 comprised of plastic, and wall brackets 104 comprised ofmetal. Plate 92 includes various channels 94 for slidably engagingplates 78 and 80 of center bracket 71, wall bracket 104, and plates 98of end caps 96. End caps 96 preferably include plates 98 for slidablyengaging plate 92 and pins 100 for attaching to the shade drive endbracket.

[0044] In accordance with another exemplary aspect of the presentinvention, FIGS. 14A-E illustrate an exemplary insertion tool 200.Insertion tool 200 may be used for assembling components of a sheetmaterial mounting device, such as shade clamp 201 and spacer support205. However, it will be appreciated that insertion tool 200 may be usedin any of several contexts. For example, insertion tool 200 may be usedto insert or assemble hardware components within an opening in a wall orsimilar structure. Insertion tool 200 may also be configured for usewith components used in microdevices, such as integrated circuits.Referring now to FIG. 14A, in accordance with one exemplary embodiment,tool 200 comprises a base member 202 having a working end 204 and ahandle end 206. One skilled in the art will appreciate that tool 200 maybe comprised of any suitable material or combinations of materials, suchas, for example, plastic, metal, wood, concrete, rock, and/or the like.In an exemplary embodiment, tool 200 is molded of Delrin. Moreover, tool200 may be comprised of a single molded, shaped, or formed unit, or itmay comprise any number of pieces permanently or releasably attached toeach other.

[0045] In accordance with one aspect of the invention, handle end 206 isconfigured to be gripped by the hand of a person, though otherembodiments of handle 206 may permit use of tool 200 by a machine orautomated device. In one embodiment, handle end 206 permits insertion ofa hand through an open center portion 208 and around handle portion 210.Handle portion 210 may comprise any suitable surface contour orconfiguration, such as rounded or bulbous, cylindrical, rectangular,conical, and/or the like. In another embodiment, center portion 208 is asolid portion which permits handle end 206 to be grasped in the palm ofthe hand. For example, in this embodiment, handle portion 210 may beheld by being pressed against the palm of the hand while the fingers ofthe hand grasp one side of center portion 208 and the thumb grasps anopposite side of center portion 208. Handle end 206 may be of anysuitable dimension or size. In one embodiment, handle end 206 is thickerthan working end 204 to suitably accommodate the grip or grasp of ahuman hand, a machine, or an automated device.

[0046] Working end 204 is distal from the handle end 206 and isconfigured to receivably engage and releasably retain a part orcomponent, such as spacer support 205, such that working end 204 and thecomponent are then capable of being inserted into and receivably engagedby an opening, such as spacer channel 245 a for example. As describedherein, the insertion of a component into a spacer channel illustratesan exemplary use for and method of using tool 200 in accordance with thepresent invention. However, tool 200 may be used to insert and adjust oralign parts or components in conjunction with other types of openings,channels, or holes having a variety of shapes or configurations, such ascircular, rectangular, square, oblong, triangular, etc., and still fallwithin the scope of the present invention. In one embodiment, workingend 204 includes a pair of spaced apart protruding members 212 which areeach configured to be inserted into or slid through the spacer channel245 a of shade clamp 201, as best illustrated in FIG. 14D. Theprotruding members 212 extend outwardly from the working end 204 of basemember 202 and may be of any suitable shape or configuration, such asrectangular, cylindrical, conical, square, and/or the like.

[0047] In one embodiment, protruding members 212 are substantiallyrectangular. In this embodiment, the protruding members 212 eachcomprise an outer edge 214, an inner edge 215, an upper surface 216, alower surface (not shown), an inner side surface 218, and an outer sidesurface 219. In one embodiment, outer edge 214 has a rounded surface. Inanother embodiment, upper surface 216 is gradually sloped upwardrelative to a level lower surface, such that thickness T of protrudingmember 212 gradually increases along the width of protruding member 212between outer edge 214 and inner edge 215. In one embodiment, uppersurface 216 is gradually sloped upward at an angle ranging from about 2degrees to about 15 degrees relative to the lower surface and thelongitudinal axis of the base member 202. Preferably, upper surface 216is sloped upward at an angle of from about 3 degrees to about 7 degreesand, more preferably, from about 3 degrees to about 4 degrees. Inanother embodiment, the lower surface (not shown) of the protrudingmember 212 is gradually sloped downward relative to a level uppersurface 216, such that thickness T of protruding member 212 graduallyincreases along the width of protruding member 212 between outer edge214 and inner edge 215. In this embodiment, the lower surface isgradually sloped at an angle ranging from about 2 degrees to about 15degrees relative to the upper surface 216 and the longitudinal axis ofthe base member 202. Preferably, the lower surface is sloped at an angleof from about 3 degrees to about 7 degrees and, more preferably, fromabout 3 degrees to about 4 degrees. In yet another embodiment, both theupper surface 216 and the lower surface of protruding member 212 aregradually sloped away from each other and relative to the longitudinalaxis of the base member 202 such that each protruding member 212 has asubstantially conical configuration.

[0048] In an exemplary embodiment, protruding members 212 are spacedapart by a recess 222 in the working end 204 of base member 202. Recess222 may be of any suitable shape or configuration, such as square,rectangular, semi-circular, and/or the like. In one embodiment, recess222 is defined by a rear surface 224 and a pair of opposing sidesurfaces 226 in the working end 204. In an exemplary embodiment,opposing side surfaces 226 each include means for engaging and retaininga spacer support 205, which means may include a plurality of retainingmembers adapted to support the spacer support 205 within recess 222, asuitably dimensioned channel or track which may be inset into each ofthe opposing side surfaces 222 and into which the spacer support 205 maybe inserted, or the like. In an alternate embodiment, rear surface 224may also include suitable means for releasably retaining spacer support205, such as retaining members or a suitably dimensioned inset channelor track. Recess 222 and the means for engaging and retaining spacersupport 205 are suitably adapted to releasably engage the spacer support205.

[0049] In one embodiment, the means for engaging and retaining a spacersupport 205 comprise a plurality of retaining members 228 extending fromeach of the opposing side surfaces 226. The retaining members 228 may bearranged in any suitable configuration capable of receivably engagingand retaining the spacer support 205 within recess 222. As illustratedin FIG. 14B, retaining members 228 may be arranged in a V-shapedconfiguration such that a pair of spaced apart upper retaining members228 a are coupled with a lower retaining member 228 b which is placedbeneath the space 230 that separates the pair of upper retaining members228 a. A space or track having height H2 is created between upperretaining members 228 a and lower retaining member 228 b. Height H2 isslightly greater than the thickness H1 of spacer support 205. In thismanner, the spaces or tracks created by the opposing side surfaces 226may stabilize and retain the spacer support 205 within the recess 222,such that when spacer support 205 is inserted within the recess 222, anupper portion, such as that provided by the retaining members 228 a,exerts a downward force on spacer support 205 while a lower portion,such as provided by retaining member 228 b, exerts an upward force onspacer support 205. Alternatively, retaining members 228 may be arrangedsuch that a pair of spaced apart upper retaining members are coupledwith a spaced apart pair of lower retaining members. In a furtherembodiment, retaining members 228 may be adapted such that a singleupper retaining member on each of the opposing sides 226 is coupled witha single lower retaining member on each of the opposing sides 226 tosuitably engage and retain spacer support 205 within recess 222. Recess222 and retaining members 228 are suitably dimensioned to permit spacersupport 205 to be slidably inserted within and removed from the recess222. In one embodiment, recess 222 has a width W2 that is slightlygreater than a width W1 of spacer support 205 and a length L2 that issubstantially similar to a length L1 of spacer support 205. One skilledin the art will appreciate that retaining members 228 illustrate anexemplary means for engaging and retaining a spacer support 205 withinrecess 222 in accordance with the present invention and that otherstructures, such as an inset track or channel within each of opposingside surfaces 226, which perform similar functions may be employed andstill fall within the scope of the present invention.

[0050] As seen in FIG. 14C, spacer support 205 may be inserted withinrecess 222 such that planar flange 250 is supported by retaining members228 and cylindrical end 225 occupies the space between the protrudingmembers 212. In one embodiment, the outer edge 227 of cylindrical end225 is substantially flush with the outer edges 214 of protrudingmembers 212. Spacer support 205 may be inserted into the tool 200 eitherwith or without a spacer cord (not shown) being inserted throughcylindrical projection 253 and/or a lift cord (not shown) being insertedthrough lift cord aperture 220.

[0051] Referring next to FIG. 14D, tool 200, with spacer support 205retained within recess 222, can be used to insert spacer support 205within spacer channel 245 a of shade clamp 201. In one embodiment, oneof the protruding members 212 of the working end 204 of tool 200 isbrought into contact with a spacer channel end 247 and is inserted orslid into spacer channel 245 a between peripheral lip 240 a and innerlip 235 a. In this embodiment, the protruding member 212 may be used toopen or slightly pry apart the lips 240 a and 235 a at one end 247 ofthe spacer channel 245 a, such that a first protruding member 212 slidesinto the spacer channel 245 a, followed by spacer support 205 and then asecond protruding member 212.

[0052] Alternatively, the working end 204 of tool 200 with spacersupport 205 retained within recess 222 may be brought into contact withthe spacer channel 245 a such that the protruding members 212 and thespacer support 205 exert a perpendicular force in the direction of arrow232 against lips 240 a and 235 a. As one skilled in the art willappreciate, in the context of using tool 200 with other types ofopenings and other types of parts or components, the working end 204 oftool 200 may be brought into contact with the outer edges of theopening, such that the protruding members 212 and the component exert aperpendicular force against the outer edges of the opening to enable thetool 200 and the component to be inserted into the opening. The tool 200may be inserted into an opening with or without the aid of an additionaltool, such as a hammer or mallet for example (not shown). In theembodiment depicted in FIG. 14D, the working end 204 of the tool 200 maybe used to insert the spacer support 205 substantially at the desiredlocation or position within the spacer channel 245 a. That is,protruding members 212 are used substantially simultaneously to open orpry apart lips 240 a and 235 a at a selected location along spacerchannel 245 a to permit the insertion of the protruding members 212 andspacer support 205 into the spacer channel 245 a. However, in either ofthese embodiments, once inserted within the spacer channel 245 a, tool200 permits the spacer support 205 to be suitably moved or selectivelypositioned within spacer channel 245 a. Thus, tool 200 may be used toselectively position spacer support 205 within the spacer channel 245 aduring the insertion step or, alternatively, the tool 200 may be used toselectively position spacer support 205 anywhere along the length ofspacer channel 245 a subsequent to the insertion step. Moreover, tool200 may be used consecutively to similarly insert and position multiplespacer supports 205 within spacer channel 245 a.

[0053] Once spacer support 205 has been suitably positioned withinspacer channel 245 a, the tool 200 may be suitably removed from thespacer channel 245 a. In one embodiment, tool 200 is removed by theexertion of a force on tool 200 that is perpendicular to and away fromthe spacer channel 245 a. In this manner, the tool 200 is pulleddirectly out of and away from the spacer channel 245 a in the directionof arrow 234 of FIG. 14E. As further illustrated in FIG. 14E, sincerecess 222 and retaining members 228 are adapted to releasably engagespacer support 205, spacer support 205 remains suitably positionedwithin spacer channel 245 a when tool 200 is removed from the spacerchannel 245 a.

[0054] Once a part or component has been inserted into the appropriateopening, such as spacer channel 245 a, the component may requireadjustment or re-alignment with respect to other components of thewindow covering system. The tool 200 also may be used to adjust orre-align these already-assembled components. The tool 200 providesleverage and a gripping surface to assist in shifting the arrangement ofassembled components. To accomplish this, the tool 200 is extended intothe opening and brought into contact with the component such that thecomponent is retained by the working end 204 and capable of being movedby the tool 200 to an alternate position within the channel or openingwithout being bound by the opening. In this manner, the tool 200 permitsadjustment and realignment of tightly fitting assembled components.

[0055] While the invention has been particularly shown and describedabove with reference to exemplary embodiments, it will be understood bythose skilled in the art that various changes in form and detail may bemade without departing from the spirit and the scope of the presentinvention and that the invention encompasses all such modifications. Nosingle feature, function, or property of any disclosed embodiment isrequired for the practice of the present invention unless specificallydescribed herein as “essential” or “critical”.

What is claimed is:
 1. A device comprising: a base member including ahandle end and a working end distal from said handle end; wherein saidworking end comprises: a recess defined by a rear surface and opposingside surfaces which are configured to receive and releasably retain acomponent; and a pair of protruding members extending outwardly fromsaid working end and spaced apart by said recess.
 2. The device of claim1 , wherein said handle end is configured to be gripped by at least oneof a human hand, a machine, and an automated device.
 3. The device ofclaim 2 , wherein said base member further comprises one of an opencenter portion and a solid center portion.
 4. The device of claim 1 ,wherein at least one of an upper surface of each of said protrudingmembers and a lower surface of each of said protruding members has anincreasing slope relative to a longitudinal axis of said base member. 5.The device of claim 1 , wherein at least one of said rear surface andsaid opposing side surfaces comprises a track configured to slidablyreceive and releasably retain the component within said recess.
 6. Thedevice of claim 1 , wherein each of said opposing side surfacescomprises a plurality of retaining members, each of which extends fromsaid opposing side surfaces and into said recess and is configured toreceive and releasably retain the component.
 7. The device of claim 6 ,wherein said plurality of retaining members is arranged in a V-shapedconfiguration.
 8. The device of claim 1 , further comprising a componentreleasably retained within said recess and between said protrudingmembers.
 9. The device of claim 8 , wherein said component comprises aspacer support.
 10. The device of claim 9 , wherein an outer edge ofsaid spacer support is substantially flush with each outer edge of saidprotruding members.
 11. A method of inserting a component into anopening, the method comprising: providing an insertion tool including ahandle end and a working end; inserting a spacer support within a recessin said working end of said insertion tool; contacting an opening withsaid insertion tool and said spacer support; inserting said spacersupport and said insertion tool within said opening; removing saidinsertion tool from said opening while leaving said spacer supportwithin said opening.
 12. The method of claim 11 , wherein the step ofcontacting said opening further comprises using said insertion tool toexert a perpendicular force against outer edges of said opening.
 13. Themethod of claim 12 , wherein the step of contacting further comprisesselectively positioning said spacer support relative to said opening.14. The method of claim 12 , wherein the step of inserting said spacersupport further comprises prying apart said outer edges with protrudingmembers of said insertion tool and inserting said spacer support andsaid protruding members through said outer edges and into said opening.15. The method of claim 14 , further comprising positioning said spacersupport within said opening after inserting said spacer support and saidprotruding members within said opening.
 16. The method of claim 14 ,wherein the step of removing further comprises applying to saidinsertion tool a perpendicular force away from said opening such thatsaid insertion tool is pulled out of said opening.
 17. The method ofclaim 12 , wherein said opening comprises a spacer channel and saidouter edges comprise lips.
 18. The method of claim 17 , wherein the stepof contacting a spacer channel further comprises contacting a spacerchannel end with a first end of said working end of said insertion tool,and wherein the step of inserting said spacer support further comprisessliding said first end, said spacer support, and a second end of saidworking end of said insertion tool into said spacer channel from saidspacer channel end.
 19. The method of claim 17 , further comprisingselectively positioning said spacer support within said spacer channelafter inserting said spacer support and said insertion tool within saidspacer channel.
 20. The method of claim 18 , wherein the step ofremoving further comprises applying to said insertion tool aperpendicular force away from said spacer channel such that saidinsertion tool is pulled out of said spacer channel.
 21. A method ofadjusting and re-aligning a component within an opening, the methodcomprising: providing an insertion tool including a handle end and aworking end; contacting an opening and a component retained within saidopening with said working end of said insertion tool; engaging saidcomponent with said working end; and moving said component to analternate location within said opening.